Door handle assembly

ABSTRACT

A door handle assembly includes a handle pivot housing and a main handle rotatably or otherwise pivotally secured within the handle pivot housing. The handle pivot housing includes handle engaging-walls defining a handle pivot cavity therebetween. At least one of the handle-engaging walls includes an integrally formed boss extending into the handle pivot cavity. The main handle includes an arm integrally formed with a pivot joint defining a pivot axis, and a counterweight. The pivot joint rotatably or otherwise pivotally secures to the boss. The counterweight and the arm are positioned on opposite sides of the pivot axis. The main handle may be configured to receive and retain a plurality of caps, which may be formed of a different material than said main handle. Each of the caps may differ in at least one of size, shape, structure, material, texture, and color.

RELATED APPLICATIONS

This application relates to and claims priority benefits from U.S.Provisional Patent Application 60/680,921 entitled “Vehicle Inside DoorHandle,” filed May 13, 2005, which is hereby incorporated by referencein its entirety.

FIELD OF THE INVENTION

Embodiments of the present invention generally relate to door handles,and more particularly, to a door handle assembly that may be used as avehicle inside

BACKGROUND OF THE INVENTION

Conventional vehicle inside door handles are susceptible to swingingopen during a crash or violent maneuver. The heavier a handle is, thefurther away its center of gravity is from its pivot axis. The furtheraway the center of gravity is from the pivot axis, the easier it is forthe door handle to swing open during an impact. As door handles becomelarger and heavier, the possibility of the door handles swinging openduring an impact increases. Thus, a need exists for a door handle thatremains closed during an impact, despite the overall weight of the doorhandle.

Additionally, various vehicles include specifically designed interiordoor handles. For example, one automobile may have a first handle style,while another may have a different style. Typically, each different typeof door handle is separately manufactured. That is, the first handlestyle is manufactured with a first mold, die, or the like, while asecond style is manufactured with a second mold, die, or the like.Separately manufacturing each door handle with different tools increasesmanufacturing time and costs.

In-mold decorating is well known. However, it is generally known thatinlays are bondable only to certain types of resins. In the past,in-molding door handles was not common practice because the resinsnecessary for bonding to the inlay were not strong enough with respectto vehicle door handle specifications.

Thus, a need exists for a system that includes components that may beuniversally used with all door handles. Further, a need exists for astrong door handle that may be decorative, yet robust and easy tomanufacture.

SUMMARY OF THE INVENTION

Embodiments of the present invention provide a door handle assembly thatmay include a handle pivot housing, a main handle, a bumper, and aplurality of caps configured to be interchangeably secured to the mainhandle. The handle pivot housing includes a bumper wall integrallyformed with handle engaging-walls defining a handle pivot cavitytherebetween. The bumper wall includes at least one mating member, suchas a slot, tab, latch, clasp, barb, snap, hook, or the like. At leastone of the handle-engaging walls includes an integrally formed bossextending into the handle pivot cavity.

The main handle may include an arm integrally formed with a pivot jointdefining a pivot axis, and a counterweight. The pivot joint rotatablysecures to the boss, and the counterweight and the arm are positioned onopposite sides of the pivot axis in order to move the center of gravitycloser to the pivot axis.

The bumper may include a mating member, so that the bumper secures tothe bumper wall proximate the counterweight through a mating betweencorresponding mating members. The bumper provides a cushioned barrierwith respect to the main handle.

The caps are configured to be snapably, latchably, or otherwiseremovably secured to the main handle. Each cap is formed of a differentmaterial than the main handle. Further, each cap may differ in size,shape structure, material, texture, or color with respect to other caps.

At least one of the handle pivot housing and the main handle may alsoinclude, or cooperate to provide, at least one positive stop that limitsmovement of the main handle within the handle pivot housing. The doorhandle assembly may also include a lock knob that maintains the pivotjoint in rotatable securement with respect to the boss.

BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWINGS

FIG. 1 illustrates an isometric rear view of a handle pivot housingaccording to an embodiment of the present invention.

FIG. 2 illustrates an isometric front view of a bumper according to anembodiment of the present invention.

FIG. 3 illustrates an isometric rear view of a bumper according to anembodiment of the present invention.

FIG. 4 illustrates an isometric front view of a handle pivot housingaccording to an embodiment of the present invention.

FIG. 5 illustrates an isometric exploded view of a handle subassemblyaccording to an embodiment of the present invention.

FIG. 6 illustrates a partial lateral view of a handle subassemblyaccording to an embodiment of the present invention.

FIG. 7 illustrates an isometric exploded view of a handle assemblyaccording to an embodiment of the present invention.

FIG. 8 illustrates an isometric view of a handle assembly according toan embodiment of the present invention.

FIG. 9 illustrates an isometric view of a handle assembly according toan embodiment of the present invention.

Before the embodiments of the invention are explained in detail, it isto be understood that the invention is not limited in its application tothe details of construction and the arrangement of the components setforth in the following description or illustrated in the drawings. Theinvention is capable of other embodiments and of being practiced orbeing carried out in various ways. Also, it is to be understood that thephraseology and terminology used herein are for the purpose ofdescription and should not be regarded as limiting. The use of“including” and “comprising” and variations thereof is meant toencompass the items listed thereafter and equivalents thereof as well asadditional items and equivalents thereof.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1 illustrates an isometric rear view of a handle pivot housing 10according to an embodiment of the present invention. The housing 10includes a lower support wall 12 integrally formed with upstandinghandle-engaging walls 14 and 16, an upstanding lock wall 18, and a rear,or bumper, wall 20. The lower support walls 12 includes a fastenerthrough-hole 22 and other features that are configured to secure thehandle base 10 to a fixed structure, such as an interior of a door. Ahandle pivot cavity 24 is defined between the two handle-engaging walls14 and 16, while a lock knob cavity 26 is defined between thehandle-engaging wall 16 and the lock wall 18. The rear wall 20 includesa channel 28 configured to receive and retain a bumper 30. A slot,opening or depression 32 is formed through the rear wall 20 and extendsinto the channel 28. The slot 32 is configured to snapably secure areciprocal structure 46 on the bumper 28, which is urged into thechannel in the direction of A.

FIG. 2 illustrates an isometric front view of the bumper 30. The bumper30 may be formed of rubber, plastic, or other such materials, andincludes lateral walls 34 integrally formed with top and bottom walls 36and 38, respectively. An inner cavity 40 may be defined between thelateral walls 34 and the top and bottom walls 36 and 38, respectively.The lateral, top, and bottom walls 34, 36, and 38, respectively areintegrally formed with a channel-engaging base 42 having lateral flanges44.

FIG. 3 illustrates an isometric rear view of the bumper 30. Aprotuberance, such as a tab, 46 outwardly extends from a rear surface 48of the channel-engaging base 42.

FIG. 4 illustrates an isometric front view of the handle pivot housing10. Referring to FIGS. 1-4, the bumper 30 is urged into the channel 28in the direction of A such that the lateral flanges 44 are slidablyreceived in notches 50 formed in the rear wall 20. The bumper 30continues to slide through the channel 28 in the direction of A, untilthe tab 46 encounters the slot 32 of the rear wall, thereby snapablysecuring the bumper 30 within the channel 28. The bumper 30 provides acushioned barrier for a handle subassembly (discussed below), andparticularly a counterweight (discussed below) while at rest and throughrotation of the handle subassembly within the handle pivot cavity 24.While the bumper 30 is shown having the tab 46, and the slot 32 isformed through the rear wall 20, the bumper 30 may, alternatively, havea slot formed therethrough, while the rear wall 20 includes a tabextending into the handle pivot cavity 24. Optionally, the bumper 30 maybe integrally formed with the rear wall 20.

FIG. 5 illustrates an isometric exploded view of a handle subassembly52. The handle subassembly 52 includes a main handle 54, a cap 56, and acounterweight 58. The main handle 54 includes an arm 60 extending from apivot joint 62. The arm 60 may be grasped by a user in order to rotatethe main handle 54 when it is rotatably secured within the handle pivothousing 10. The pivot joint 62 includes a boss opening 64 configured torotatably retain a boss extending from the handle-engaging wall 14 ofthe handle pivot housing 10 (shown, e.g., in FIGS. 1-4). Additionally,the main handle 54 includes one or more protuberances 65 extending fromone or both lateral surfaces 66.

The cap 56 may be chrome plated, painted, molded in different colors,decorated with graphics according to any number of different methods,or, preferably, in-mold decorated. The cap 56 includes lateral walls 72integrally formed with a top wall 74 and blunted end 76. Slots 78 may beformed through portions of at least one of the lateral walls 72. The cap56 is configured to snapably, latchably, or otherwise removably secureto the main handle 54 by way of the slots 78 securely engaging theprotuberances 65 of the main handle 54. In particular, the blunted end76 of the cap 56 is positioned around a portion of the distal end 82 ofthe main handle 54, and the cap 56 is pivoted in the direction of arc Babout the distal end 82, until the slots 78 snapably secure around theprotuberances 65, and the proximal lip 84 of the cap 56 snapably securesaround a corresponding edge 86 of the main handle 54. Additionally, theblunted end 76 of the cap 56 may snapably, latchably, or otherwiseengage around a corresponding structure located at the distal end 82 ofthe main handle 54. Alternatively, the protuberances 65 of the mainhandle 54 may be slots, while the slots 78 of the cap 56 may beprotuberances. In other embodiments, corresponding structure on the capand the handle may be utilized for a snap-fit or other latchingarrangements.

A variety of caps 56 having different ornamentation and styles may beused with the handle subassembly 52. Each cap 56 may include slots,tabs, and the like that allow it to secure to the main handle 54. Thus,one type of main handle 54 may be manufactured, and a wide variety ofcaps 56 may be used with that type of main handle 54.

The main handle 54 may be manufactured from a different material thanthe cap 56, because the main handle 54 is separate and distinct from thecap 56. For example, the main handle 54 may be formed of a relativelystrong material, such as plastic or glass-filled nylon with mineraladditives; while the cap may be made with a different material suitablefor decoration, such as a compounded thermoplastic, like ABS or similarmaterials. Despite the nature of the cap 56, the handle subassembly 52meets desired vehicle door handle specifications because of the strengthof the underlying main handle 54.

Once the cap 56 is secured to the main handle 54, the counterweight 58is urged into a counterweight housing 88 extending from a proximal endof the pivot joint 62 in the direction of C. The counterweight 58 may bemade of any suitable material, such as, for example, a zinc alloy,aluminum, or the like. The handle subassembly 52 is configured toreceive the counterweight 58 through the housing 88, support, end, orthe like, in order to provide an anti-opening assembly. A fin 94 extendsupwardly from the counterweight 58. The counterweight 58 is moved intothe housing 88 until an upper tab 90 snapably secures into acorresponding slot 92 of the housing 88. The counterweight 58 andhousing 88 may also include additional features that assist in securingthe counterweight into the housing 88. Optionally, the counterweight 58may include a slot, while the housing 88 includes a corresponding tab.Alternatively, the counterweight 58 and the housing 88 may be integrallyformed as a single unit. Also, the counterweight 58 may be secured tothe handle subassembly in a variety of ways. For example, thecounterweight 58 may be snapped onto the housing 88 from above or below,and/or the counterweight 58 may be bonded or latched to the housing 88.

FIG. 6 illustrates a partial lateral view of the handle subassembly 52.As shown in FIG. 6, once the counterweight 58 is secured within thehousing 88, the fin 94 abuts the lip 84 of the cap 56, thereby securingthe cap 56 into position. As such, the main handle 54 and cap 56 areprecluded from rotating in the direction of arc D with respect to thecounterweight 58 and housing 88. The lock created by the fin 94 abuttingthe lip 84 ensures that the cap 56 remains on the main handle 54 duringthermo-cycle testing, material thermo-expansion and contraction andoperation.

FIG. 7 illustrates an isometric exploded view of a handle assembly 96.In order to assemble the handle assembly 96, the pivot joint 62 of thehandle subassembly 52 is positioned in the handle pivot cavity 24 of thehandle pivot housing 10 such that the boss opening 64 securely androtatably engages the boss 98 extending from the handle engaging wall14. The boss 98 is integrally molded with the handle pivot housing 10. Alock knob 100 is then secured within the lock knob cavity 26 of thehandle pivot housing 10. The lock knob 100 includes a lateral wall 102integrally formed with an arcuate upper wall 104. The arcuate upper wall104 overlays a portion 106 of the main handle 54 or cap 56.

After the handle assembly 96 is assembled, the handle subassembly 52 maypivot about the boss 98. The lock knob 100 can assist to ensure that thehandle subassembly 52 remains rotatably secured to the boss 98. That is,the lock knob 100 can act as a barrier past which the handle subassembly52, particularly the portion 106 covered by the upper arcuate wall 104,cannot slide past.

FIG. 8 illustrates an isometric view of the handle assembly 96. As shownin FIGS. 5-8, the counterweight 58 is positioned on the opposite side ofthe pivot axis (that is, the boss 98) from the arm 60. The position ofthe counterweight 58, therefore, moves the center of gravity of thehandle subassembly 52 closer to the pivot axis. Additionally, the cap 56may be removed and another cap, having a different design,ornamentation, surface, or formed of a different material, may besecured to the main handle 54.

Referring to FIGS. 4-8, the handle assembly 96 may include a pluralityof positive stops. For example, the pivot housing 10 may include aprotruding block 107 (shown, for example, in FIG. 4) configured to abuta curved lower tip 109 (shown, for example, in FIG. 5) of the handleassembly 52. When the handle subassembly 52 is rotated relative to thehandle pivot housing 10, the curved lower tip 109 is rotated intoabutment with the block 107, thereby halting further rotation.Additionally, the handle pivot housing 10 may include a ramped surface111 (shown, for example, in FIG. 1) that is steeper than adjoiningsurfaces. When the handle subassembly 52 is rotated relative to thehandle pivot housing 10, the inside edge 86 (shown, for example, in FIG.5) may be rotated into abutment with the ramped surface 111, whichserves as a dwell for the inside edge 86. The handle assembly 96 mayinclude more or less positive stops or dwells than those shown anddescribed.

FIG. 9 illustrates an isometric view of a handle assembly 110 accordingto an embodiment of the present invention. The handle assembly 110includes a handle pivot housing 112 that pivotally supports a handlesubassembly 114. A lock knob 116 ensures that the handle subassembly 114remains pivotally secured within the handle pivot housing 112. Acounterweight 118 on the opposite side of the pivot axis than the arm120 of the handle subassembly 114 provides a center of gravity closer tothe pivot axis than the distal end of the handle subassembly 114. Asshown in FIG. 9, the cap 122 does not include slots formed throughlateral surfaces. Instead, the cap 122 may include interior ridges orledges that snapably secure to reciprocal structures formed in the mainhandle (covered by cap 122). Additionally, the counterweight 118 may bebulkier and heavier than the counterweight 58 (shown, for example, inFIG. 5). Also, the counterweight 1118 may include a downwardly extendingrib that mates with a slot (not shown) formed in a counterweight housingor support so that the counterweight 118 may be secured above thecounterweight housing or support.

Thus, embodiments of the present invention provide a door handleassembly that remains closed during an impact, despite the overallweight of the door handle. Because embodiments of the present inventionprovide a door handle assembly having a center of gravity that is closerto the pivot axis, the door handle assembly is less susceptible toaccidentally swinging open during an impact, as compared to previousdoor handles.

Additionally, embodiments of the prevent invention provide a door handleassembly that includes components, such as the handle pivot housing andthe main handle, that may be universally used with all door handles. Forexample, one ornamental handle design may use a first cap with the mainhandle, while another ornamental design may use a second cap with themain handle. Overall, all portions of the door handle assembly, with theexception of the caps, may be manufactured using the same tools andprocesses. Moreover, embodiments of the present invention provide asystem that may be decorative, yet robust and easy to manufacture.

According to one embodiment of the present invention, an in-molddecorative cap is provided for a door handle assembly. An inlaydecorative film is place into a mold. A resin material is shot into themold so that the film is joined to the resin material through themolding process. A chemical bond is created between the film and resinmaterial to create a thermo-formed cap. The cap is then secured to themain handle to provide a handle subassembly. The handle subassembly isthen assembled to the housing. In this way, various decorative caps canbe utilized in accordance with the present invention.

While terms such as front, lateral, rear, upper, lower, and the like maybe used to describe various components of embodiments of the presentinvention, it is understood that such terms are relative and are merelyto describe components in relation to the drawings. The orientations,however, may be changed, such that the front is rear or lateral, whileupper may be lower, and the like.

Variations and modifications of the foregoing are within the scope ofthe present invention. It is understood that the invention disclosed anddefined herein extends to all alternative combinations of two or more ofthe individual features mentioned or evident from the text and/ordrawings. All of these different combinations constitute variousalternative aspects of the present invention. The embodiments describedherein explain the best modes known for practicing the invention andwill enable others skilled in the art to utilize the invention. Theclaims are to be construed to include alternative embodiments to theextent permitted by the prior art.

Various features of the invention are set forth in the following claims.

1. A door handle assembly comprising: a handle pivot housing comprisinghandle engaging-walls defining a handle pivot cavity therebetween, atleast one of said handle-engaging walls comprising an integrally formedboss extending into said handle pivot cavity; a main handle comprisingan arm integrally formed with a pivot joint defining a pivot axis, saidpivot joint rotatably securing to said boss; and a cap secured to saidmain handle, said cap being made of a different material than said mainhandle.
 2. The door handle assembly of claim 1, wherein said cap issnapably secured to said main handle.
 3. The door handle assembly ofclaim 1, further comprising a counterweight, said counterweight and saidarm being positioned on opposite sides of said pivot axis.
 4. (canceled)5. The door handle assembly of claim 3, further comprising a bumpercomprising a first mating member, said handle pivot housing furthercomprising a bumper wall integrally formed with said handle-engagingwalls, said bumper wall comprising a second mating member, said bumpersecuring to said bumper wall through said first mating member matingwith said second mating member, wherein said bumper provides a cushionedbarrier with respect to said main handle, and wherein said bumper issecured to said bumper wall proximate said counterweight.
 6. The doorhandle assembly of claim 1, further comprising a bumper comprising afirst mating member, said handle pivot housing further comprising abumper wall integrally formed with said handle-engaging walls, saidbumper wall comprising a second mating member, said bumper securing tosaid bumper wall through said first mating member mating with saidsecond mating member, wherein said bumper provides a cushioned barrierwith respect to said main handle.
 7. The door handle assembly of claim6, wherein said first mating member is one of a tab and slot, andwherein said second mating member is an opposite one of said tab andsaid slot.
 8. The door handle assembly of claim 1, wherein at least oneof said handle pivot housing and said main handle further comprises atleast one positive stop that limits movement of said main handle withinsaid handle pivot housing.
 9. The door handle assembly of claim 1,further comprising a lock knob that assists in maintaining said pivotjoint in rotatable securement with respect to said boss.
 10. A doorhandle assembly comprising: a handle pivot housing comprising handleengaging-walls defining a handle pivot cavity therebetween, at least oneof said handle-engaging walls comprising an integrally formed bossextending into said handle pivot cavity; a main handle comprising an armintegrally formed with a pivot joint defining a pivot axis, said pivotjoint rotatably securing to said boss; and a first cap secured to saidmain handle, said first cap being formed of a different material thansaid main handle, said first cap being an in-mold decorated cap formedas a molded cap with an inlay decorative piece.
 11. The door handleassembly of claim 10, wherein said first cap is snapably secured to saidmain handle.
 12. The door handle assembly of claim 11, wherein saidfirst cap includes a first end positioned around a portion of a firstend of said main handle, and wherein said first cap further includes asecond end having a lip positioned around a second end of said mainhandle.
 13. The door handle assembly of claim 11, further comprising asecond cap configured to be secured to said main handle, such that saidfirst cap and said second cap are interchangeable with respect to saidmain handle, and wherein said first and second caps differ in at leastone of size, shape, structure, material, texture, and color.
 14. Thedoor handle assembly of claim 10, further comprising a counterweight,said counterweight and said arm being positioned on opposite sides ofsaid pivot axis.
 15. (canceled)
 16. The door handle assembly of claim14, further comprising a bumper comprising a first mating member, saidhandle pivot housing further comprising a bumper wall integrally formedwith said handle-engaging walls, said bumper wall comprising a secondmating member, said bumper securing to said bumper wall through saidfirst mating member mating with said second mating member, wherein saidbumper provides a cushioned barrier with respect to said main handle,and wherein said bumper is secured to said bumper wall proximate saidcounterweight.
 17. The door handle assembly of claim 10, furthercomprising a bumper comprising a first mating member, said handle pivothousing further comprising a bumper wall integrally formed with saidhandle-engaging walls, said bumper wall comprising a second matingmember, said bumper securing to said bumper wall through said firstmating member mating with said second mating member, wherein said bumperprovides a cushioned barrier with respect to said main handle.
 18. Thedoor handle assembly of claim 17, wherein said first mating member isone of a tab and slot, and wherein said second mating member is anopposite one of said tab and said slot.
 19. The door handle assembly ofclaim 10, wherein at least one of said handle pivot housing and saidmain handle further comprises at least one positive stop that limitsmovement of said main handle within said handle pivot housing.
 20. Thedoor handle assembly of claim 10, further comprising a lock knob thatassists in maintain said pivot joint in rotatable securement withrespect to said boss.
 21. A method of making a door handle assembly,said method comprising the steps of: placing an inlay decorative filminto a mold; molding a cap in the mold about the inlay the creating athermo-formed cap; securing the cap to a handle to provide a handlesubassembly; and placing the handle subassembly in a handle pivothousing.
 22. The method of claim 21, wherein the cap is snap-fitted tothe handle.
 23. The method of claim 21, wherein the handle subassemblyincludes a counterweight housing, and the method further comprisesplacing a counterweight in the counterweight housing.
 24. The method ofclaim 23, wherein the counterweight is adapted to abut the cap tofurther secure the cap to the handle.
 25. The method of claim 23,wherein the handle pivot housing includes a bumper wall having a firstmating member, and the method further comprises securing a bumper with asecond mating member on the bumper wall through mating engagement of thefirst mating member and the second mating member.
 26. The method ofclaim 25, wherein the bumper is secured to the bumper wall proximatesaid counterweight.